Electrical connector assembly

ABSTRACT

An electrical connector assembly including a mounting ring having an interior region, a sealing surface at one axial end for securing to a surface, and a securement rim at an opposite axial end. A connector body having engagement surfaces can engage and seal to the mounting ring. The connector body can include electrical terminals extending into the interior region of the mounting ring for engaging mating electrical terminals.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/800,534, filed on May 15, 2006, U.S. Provisional Application No.60/849,633, filed on Oct. 5, 2006, and U.S. Provisional Application No.60/920,382, filed on Mar. 28, 2007. The entire teachings of the aboveapplications are incorporated herein by reference.

BACKGROUND

Solar panels are typically electrically connected together on siteduring installation. Current methods tend to be labor intensive and mayinclude soldering on site. As a result, installation can be timeconsuming.

SUMMARY

The present invention can provide an electrical connector assembly thatcan allow solar panels to be electrically connected together easily andquickly.

The electrical connector assembly can include a mounting ring having aninterior region, a sealing surface at one axial end for securing to asurface, and a securement rim at an opposite axial end. A connector bodyhaving engagement surfaces can engage and seal to the mounting ring. Theconnector body can include electrical terminals extending into theinterior region of the mounting ring for engaging mating electricalterminals.

In particular embodiments, the connector body can engage and lock to thesecurement rim of the mounting ring. The mounting ring can include anadhesive layer on the sealing surface. The mounting ring can engage arecess in the connector body. The connector body can include an adhesivelayer. The electrical terminals can include at least four femaleelectrical terminals with circular resilient sockets. The femaleelectrical terminals can be electrically connected in electricalcircuitry including bypass circuitry. The electrical circuitry caninclude diodes. A removable cover can provide access to the electricalcircuitry. The electrical terminals can be electrically connected tocables extending from the connector body. The electrical connectorassembly can further include a solar panel having an electricalconnection region with protruding circular male terminals. The mountingring can be secured around the electrical connection region whereby thecircular male terminals protrude into the interior region of themounting ring for engagement with female electrical terminals of theconnector body which have circular resilient sockets. A laminatingmaterial can be applied and can be turned into liquid form to surroundthe mounting ring. The mounting ring can block entry of the laminatingmaterial into the electrical connection region.

The present invention can also provide an electrical connector assemblyincluding an electrical connector body and female electrical terminalswith circular resilient sockets contained within the body. The circularresilient sockets can be positioned along an electrical engagement faceof the body. The electrical engagement face can have a planar sealingsurface surrounding the circular resilient sockets for engaging asurface and sealing around the circular resilient sockets.

In particular embodiments, an adhesive layer can be included on theplanar sealing surface. The female electrical terminals can beelectrically connected in electrical circuitry including bypasscircuitry. The electrical circuitry can include diodes. The electricalterminals can be electrically connected to a circuit board containingthe electrical circuitry. A removable cover can provide access to theelectrical circuitry. The electrical cables can be electricallyconnected to the electrical terminals and extend from the connectorbody. The electrical connector assembly can further include a solarpanel having an electrical connection region with protruding circularmale terminals for engagement with the circular resilient sockets of thefemale electrical terminals. The solar panel can include laminatingmaterial. The connector body can be positioned within a hole in thelaminating material for engaging the circular male terminals. Thecircular male terminals can be located at a bottom of the hole.

The present invention can also provide an electrical connector assemblyincluding an enclosed housing having an openable access cover coveringan access opening. An electrical engagement face can be positioned onthe housing opposite to the access opening. At least one electricalconnection opening can extend through the electrical engagement face. Anelectrical connector board can have electrical terminals secured thereonand can be insertable within the housing through the access opening. Aself locking and alignment arrangement can lock the electrical connectorboard within the housing and align the electrical terminals with the atleast one electrical connection opening of the electrical engagementface for engaging mating electrical terminals protruding through the atleast one opening in the electrical engagement face.

In particular embodiments, an adhesive layer can be on the electricalengagement face and surround the at least one opening for securing thehousing to a surface. A pressure relief valve can be included on thehousing for relieving pressure differences within the housing. Theelectrical terminals on the electrical connector board can be femaleelectrical terminals with circular resilient sockets. The at least oneelectrical connection opening can include a series of electricalconnection openings. The circular resilient sockets can be aligned withcorresponding electrical connection openings. The female electricalterminals can be electrically connected in electrical circuitryincluding bypass circuitry. The electrical circuitry can include diodes.The electrical terminals can be electrically connected to a circuitboard containing the electrical circuitry. The electrical terminals canbe mounted to the electrical connection connector board in alignmentwith visual alignment holes extending through the electrical connectorboard for allowing visual alignment of the circular resilient socketswith mating male electrical terminals. The locking and alignmentarrangement can include self-locking protrusions extending from thehousing which engage corresponding locking holes in the electricalconnector board. The electrical connector assembly can also include asolar panel having an electrical connection region with protrudingcircular male terminals extending through corresponding electricalconnection openings in the electrical engagement face for engagementwith the circular resilient sockets of the female electrical terminals.The solar panel can include laminating material. The housing can bepositioned within a hole in the laminating material from engaging thecircular male terminals. The circular male terminals can be located at abottom of the hole.

The present invention can also provide a method of forming an electricalconnection with an electrical connector assembly having a mounting ringand a connector body. The mounting ring can be secured to a surface. Themounting ring can have an interior region, a sealing surface at oneaxial end for securing to the surface, and a securement rim at anopposite axial end. Engagement surfaces of the connector body can beengaged and sealed to the mounting ring. The connector body can includeelectrical terminals extending into the interior region of the mountingring which engage mating electrical terminals protruding from thesurface into the interior of the mounting ring.

In particular embodiments, the connector body can be engaged and lockedto the securement rim of the mounting ring. The mounting ring can besecured to the surface with an adhesive layer on the sealing surface.The mounting ring can be engaged in a recess in the connector body. Theconnector body can be provided with an adhesive layer. The electricalterminals include at least four female electrical terminals havingcircular resilient sockets. The female electrical terminals can beelectrically connected in electrical circuitry including bypasscircuitry. An electrical circuitry can include diodes. A removable covercan provide access to the electrical circuitry. The electrical terminalscan be electrically connected to cables extending from the connectorbody. The mounting ring can be secured around an electrical connectionregion of a solar panel having circular male terminals which protrudeinto the interior region of the mounting ring and engage femaleelectrical terminals of the connector body having circular resilientsockets. Laminating material can be applied and can be turned intoliquid form to surround the mounting ring. The mounting ring can blockentry of the laminating material into the electrical connection region.

The present invention can also provide a method of forming an electricalconnection with an electrical connector assembly. Female electricalterminals with circular resilient sockets can be contained within anelectrical connector body. The circular resilient sockets can bepositioned along an electrical engagement face of the body. TheElectrical engagement face can have a planar sealing surface surroundingthe circular resilient sockets. The sealing surface of the electricalengagement face can engage a surface for sealing around the circularresilient sockets and for electrically engaging the circular resilientsockets with mating male circular terminals protruding from the surface.

In particular embodiments, the electrical engagement face can be securedto the surface with an adhesive layer on the planar sealing surface. Thefemale electrical terminals can be electrically connected in electricalcircuitry including bypass circuitry. The electrical circuitry caninclude diodes. The female electrical terminals can be electricallyconnected to a circuit board containing the electrical circuitry. Aremovable cover can provide access to the electrical circuitry. Thefemale electrical terminals can be electrically connected to electricalcables extending from the connector body. The electrical connector bodycan be electrically connected to a solar panel having an electricalconnection region at which the mating circular male terminals protrudefrom the surface. The solar panel can include laminating material andthe connector body can be positioned within a hole in the laminatingmaterial for engaging the circular male terminals. The circular maleterminals can be located at a bottom of the hole.

The present invention can also provide method of forming an electricalconnection with an electrical connector assembly in which an enclosedhousing can be provided having an openable access cover covering anaccess opening. An electrical engagement face can be positioned on thehousing opposite the access opening. At least one electrical connectionopening can extend through the electrical engagement face. An electricalconnector board having electrical terminals secured thereon can beinserted within the housing through the access opening. The electricalconnector board can be locked within the housing and align theelectrical terminals with the at least one electrical connection openingof the electrical engagement face with a self-locking and alignmentarrangement, to engage mating electrical terminals that protrude throughthe at least one electrical connection opening in the electricalengagement face.

In particular embodiments, the housing can be secured to a surface withan adhesive layer on the electrical engagement face surrounding the atleast one electrical connection opening. Pressure differences within thehousing can be relieved by a pressure relief valve. The electricalterminals on the electrical connector board can be female electricalterminals with circular resilient sockets. The at least one electricalconnection opening can include a series of electrical connectionopenings. The circular resilient sockets can be aligned withcorresponding electrical connection openings. The female electricalterminals can be electrically connected in electrical circuitryincluding bypass circuitry. The electrical circuitry can include diodes.The female electrical terminals can be electrically connected to acircuit board containing the electrical circuitry. The female electricalterminals can be mounted to the electrical connector board in alignmentwith visual alignment holes extending through the electrical connectorboard for allowing visual alignment of the circular resilient socketswith mating male electrical terminals. Self-locking protrusions of theself-locking and alignment arrangement can extend from the housing andengage corresponding locking holes in the electrical connector board.The housing can be electrically connected to a solar panel having anelectrical connection region at which the mating electrical terminalsare circular male terminals protruding from the surface at theelectrical connection region into respective electrical connectionopenings for engaging corresponding circular resilient sockets. Thesolar panel can include laminating material. The housing can bepositioned within a hole in the laminating material for engaging thecircular male terminals. The circular male terminals can be located at abottom of the hole.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing will be apparent from the following more particulardescription of example embodiments of the invention, as illustrated inthe accompanying drawings in which like reference characters refer tothe same parts throughout the different views. The drawings are notnecessarily to scale, emphasis instead being placed upon illustratingembodiments of the present invention.

FIG. 1 is a drawing of a portion of a solar panel.

FIG. 2 is a perspective view of an electrical connection region of thesolar panel.

FIGS. 3 and 4 are perspective see through views of an embodiment of anelectrical connector assembly.

FIG. 5 is a side see through view of a portion of the electricalconnector assembly of FIGS. 3 and 4.

FIG. 6 is a bottom view of the electrical connector assembly of FIGS. 3and 4.

FIG. 7 is a side view of a housing member ring extending around anelectrical connection region and surrounded by laminating material.

FIG. 8 is a top perspective see through view of another embodiment of anelectrical connector assembly.

FIG. 9 is bottom perspective see through view of the electricalconnector assembly of FIG. 8.

FIG. 10 is an exploded view of the electrical connector assembly of FIG.8.

FIG. 11 is a perspective view of a portion of an embodiment of a femaleelectrical connector.

FIG. 12 is a perspective view of another embodiment of a femaleelectrical connector.

FIG. 13 is a top see through view of another embodiment of an electricalconnector assembly.

FIG. 14 is a bottom see through view of the electrical connectorassembly of FIG. 13.

FIG. 15 is an exploded view of the electrical connector assembly of FIG.13.

FIG. 16 is a perspective view of a portion of a solar panel with yetanother embodiment of an electrical connector assembly.

FIG. 17 is a plan view of the electrical connector assembly of FIG. 16on a solar panel with the top removed.

FIG. 18 is a sectional view through a laminated solar panel showing theelectrical connector assembly of FIG. 16.

FIG. 19 is a perspective view of the electrical connector assembly ofFIG. 16.

FIG. 20 is a bottom view of the electrical connector assembly of FIG.16.

FIG. 21 is a partial sectional view of the electrical connector assemblyof FIG. 16 positioned within a hole in the laminating material of thesolar panel.

FIG. 22 is a bottom view of a square ring.

FIG. 23 is a plan view of another embodiment of an electrical connectorassembly on a solar panel.

FIG. 24 is a sectional view through a laminated solar panel showing theelectrical connector assembly of FIG. 23.

FIG. 25 is a perspective view of the electrical connector assembly ofFIG. 23.

FIG. 26 is a bottom view of the electrical connector assembly of FIG.23.

FIG. 27 is a partial sectional view of the electrical connector assemblyof FIG. 23 positioned within a hole in the laminating material of thesolar panel.

FIG. 28 is a perspective view of another electrical connector assembly.

FIG. 29 is a perspective view of the electrical connector assembly ofFIG. 28 with the cover removed to show a circuit board.

FIG. 30 is a perspective view of the electrical connector assembly ofFIG. 28 with the cover and circuit board removed.

FIG. 31 is a bottom view of the electrical connector assembly of FIG.28.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, solar panel 10 has a series of solar cells12 that are electrically connected to conductors 14. Selected conductors14 can terminate at, or be electrically connected to electricalterminals 16 a which can protrude from a planar mounting surface 38located at an electrical connection region 16, often at the back of thesolar panel 10. There typically can be two or more electrical terminals16 a, with four being shown in FIG. 1 as an example. The electricalterminals 16 a can be male circular snap button electrical connectorterminals that are soldered or otherwise secured to the conductors 14and secured to the surface 38 of the electrical connection region 16.The male electrical terminals 16 a can be similar to those disclosed inU.S. Pat. No. 7,083,481, the contents of which are incorporated hereinby reference in its entirety. Alternatively, other suitable electricalconnector terminals can be used. The solar panel 10 can be covered withlaminating materials 34 (FIG. 7) which can seal out moisture. Thelaminating material 34 can include a polymeric material such as ethylvinyl acetate (EVA), and also can include or be laminated with a backingsuch as a polyvinyl fluoride (PVF) backing or glass backing 35. Thelaminating material 34 can be applied in a sheet and turned into meltedliquid form during processing under heat and pressure during lamination.

Referring to FIGS. 3-7, electrical junction or connector assembly 20 isone embodiment of an electrical connector assembly which can be employedto allow electrical connections to be easily and quickly made to solarpanels 10 on site. The electrical connector assembly 20 can include aconnector body 18 with a rounded or circular nose 18 a which housesfemale electrical connectors 27, for example two, having femaleelectrical terminals 22, within respective recesses 22 a positioned onan electrical engagement face 21, which can be planar. The recesses 22 acan be sized for each female electrical terminal 22, or alternatively,one large recess can be employed for housing both female electricalterminals 22. The female electrical terminals 22 can have resilientfemale circular connector sockets 23 with a circular pattern ofresilient contact tabs 23 a (FIG. 11), for engaging the male electricalterminals 16 a (FIG. 6), for example two, for electrical connectiontherebetween. The electrical connectors 27 can be similar to thosedisclosed in U.S. Pat. No. 6,520,812, the contents of which areincorporated herein by reference in its entirety. The electricalconnectors 27 can have securement portions 26, such as a crimping regionwith crimping tabs for electrical connection to respective electricalcables, wires or conductors 24. The electrical cables 24 can extend fromthe rear 18 b of the body 18 for electrical connection to desiredlocations and components. The electrical cables 24 can electricallyconnect the solar panel 10 to other solar panels to create an array,which can be in series or in parallel.

The electrical connector assembly 20 can include a mounting, securement,or housing member 30 such as a ring. The ring 30 can be circular ortubular in shape, and have a wall surrounding an interior region orcavity 36, a sealing surface 29 at one axial end, and a securement rim31 at the opposite axial end. The securement rim 31 can be mechanicallyengageable or lockable in a sealed manner with engagement surfaces suchas a circular recess or annular groove 28 on the bottom of the body 18.The sealing surface 29 of the ring 30 can be adhered to the surface 38of the solar panel 10 at the electrical connection region 16 around themale electrical terminals 16 a. The ring 30 can be adhered before thelaminating material 34 is applied. The ring 30 can include an adhesivelayer 30 a, for example double sided adhesive tape, or an adhesive layercovered by release paper 30 b (FIG. 5). The release paper 30 b can beremoved to allow the ring 30 to be adhered to the surface 38 around theelectrical terminals 16 a. Alternatively, the ring 30 can be adhered byan adhesive or sealant applied at the time the ring 30 is adhered. Thelaminating material 34 can then be applied and turned into liquid formover the solar panel 10. The sealing surface 29 at the bottom of thering 30 with the adhesive layer 30 a can seal against surface 38 whichcan block or prevent the entry or intrusion of the laminating material34 into the electrical connection region 16. The electrical terminals 16a can be secured to the surface 38 before the ring 30 and laminatingmaterial 34 is applied, or alternatively, can be secured later. The ring30 can have a height greater than the height of the laminating material34, and can provide a barrier or dam for the laminating material 34 sothat the electrical connection region 16 does not become covered withlaminating material 34, thereby allowing access to the male electricalterminals 16 a for electrical connection. The height of the ring 30 candepend upon the thickness of the laminating material 34 and backing 35,and can protrude above the laminating material 34 and backing 35 forsecurement to the connector body 18. The male electrical terminals 16 acan have a height that is less than the ring 30 and of the laminatingmaterial 34. Consequently, the ring 30 can allow access to the maleelectrical terminals 16 a within cavity 36.

When the laminating material 34 has hardened, forming a hole 33 andsealing to and around the ring 30, the body 18 of the electricalconnector assembly can be engaged with the ring 30 by engaging securing,locking or snapping the groove 28 over the engagement rim 31 of the ring30 and extending the female electrical terminals 22 into the interiorregion 36 of the ring 30 and into engagement with the protruding maleelectrical terminals 16 a at the bottom of the hole 33. Alternatively,the laminating material 34 and backing 35 can be first applied to thesolar panel 10, and a hole 33 can be later cut to expose the electricalconnection region 16. The ring 30 can then be positioned, secured, andsealed within the hole 33 to the laminating material for engagement withthe body 18.

The engagement rim 31 of the ring 30 and the groove 28 can be configuredto have locking and/or water sealing features. Additionally, sealantmaterial, for example silicone, can be added to increase the sealingcapabilities. The bottom of the body 18 on the electrical engagementface 21 can include an adhesive layer 32 surrounding the groove 28 foradhering the body 18 to the laminating material 34 or backing 35 (FIG.7). This can provide additional securement and sealing capabilities,including a planar sealing surface 83, on the electrical engagement face21 surrounding the female circular connector sockets 23 of the femaleelectrical terminals 22 for sealing out moisture. Sealant material canalso be added between the body 18 and the laminating material 34 orbacking 35. If the ring 30 is applied to the surface 38 after the maleelectrical terminals 16 a are in place, a locating fixture or jig can beused to locate the ring 30 into the proper position relative to the maleelectrical terminals 16 a. Alternately, if the male electrical terminals16 a are secured or soldered to surface 38 after the ring 30 is securedin place, a locating fixture or jig can be used to solder the maleelectrical terminals 16 a in the proper position relative to each otherand the ring 30. The male electrical terminals 16 a can protrude fromthe surface 38 of the electrical connection region 16 into the interiorregion 36 of the ring 30. In some embodiments, the groove 28 in body 18can be replaced with a cavity in which the diameter of the cavityengages or snaps onto the ring 30. The body 18 and the ring 30 can bemade of insulative material such as polymers, plastics or ceramics. Thebody 18 can have openings 24 a to allow the passage of the electricalcables 24, or which alternatively, can be formed by molding the body 18over the electrical cables 24.

Consequently, the solar panels 10 can be shipped with the electricalconnection region 16 having the configuration shown in FIG. 7 so thatelectrical connections between solar panels 10 can be made by engagingor snapping the bodies 18 of the electrical connector assemblies 20 inplace onto the rings 30, whereby the sockets 23 of the female electricalterminals 22 on electrical engagement face 21 extend into the cavity 36of ring 30 and also engage the male electrical terminals 16 a which arelocated below the laminating material 34 in the cavity 36 surrounded byring 30. At the same time, the hole 33 and cavity 36 surrounding themale electrical terminals 16 a can be sealed in a watertight manner. Themale electrical terminals 16 a can have heads 16 b which are wider thanthe lower portions 16 c for locking the female terminals 22 to the maleelectrical terminals 16 a. This can reduce the possibility of unwanteddisengagement, for example by heat related expansion and contraction. Asa result, the electrical connector assembly 20 and connector body 18 canbe quickly and easily secured with both electrical and mechanicalengagement in a sealed or watertight manner for electrically connectingsolar panels 10 together. The solar panels 10 can be shipped with aprotective removable cover 37 (FIG. 7) which can engage the ring 30 andcover the electrical connection region 16.

FIGS. 8-12 depict another embodiment of an electrical junction orconnector assembly 40 which can have a body 42 with a circular shape.The electrical connector assembly 40 differs from electrical connectorassembly 20 in that a removable access cover 54 can be secured to thetop of the body 42 within a recess 58 by screws 46 within holes 54 a and58 a. The cover 54 and recess 58 can be shaped to have a close fit andcan include a gasket for sealing purposes. The access cover 54 canprovide access to the inner components and circuitry of the electricalconnector assembly 40. The engagement rim 31 of the ring 30 can have anannular shoulder 31 a for sealing and/or locking purposes. Theelectrical connector assembly 40 can have at least four femaleelectrical terminals 22 within recesses 22 a on electrical engagementface 21 for mating with corresponding at least four male electricalterminals 16 a on the solar panel 10. The four electrical terminals 22can be provided on two single female electrical connectors 27 and on adual female electrical connector 50 (FIGS. 10-12). The two femaleelectrical connectors 27 can be electrically connected to cables 24 atthe securement portions 26. The opposite end of each female electricalconnector 27 can include a connection portion 25 which can beelectrically connected to a lead 48 a at one end of a diode 48. Theleads 48 a at the opposite end of each diode 48 can be electricallyconnected to the connection portions 25 on the dual electrical connector50. The leads 48 a can be secured to the connection portions 25 byscrews 46. Washers can be employed if necessary. The diodes 48 can bepositioned within a recess 44 within the body 42. The diodes 48 can beaccessed by removing the cover 54, allowing replacement of the diodes aswell as other components when necessary. The dual electrical connector50 can have a jumper 52 electrically connecting the two femaleelectrical terminals 22 together, which can be stamped from the samematerial as the electrical terminals 22. Alternatively, the electricalterminals 22 can be separate components that are then connected togetherto function as the dual electrical connector 50.

The electrical connector assembly 40 can be secured and connected tosolar panel 10 in a similar manner as previously described. Theelectrical conductors 14 and four male terminals 16 a can beappropriately electrically configured on the solar panel 10, and thefemale electrical terminals and electrical circuit of connector assembly40 can be electrically connected or arranged, to provide electricalbypass circuitry. As a result, when the solar panel 10 is shaded, orwhen solar cells 12 are damaged, the diodes 48 can direct electricityaway from the solar panel 10 so that non productive solar panels 10 donot draw power away from other productive solar panels 10. In someembodiments, the connectors 27 and 50 can be positioned within a singlecavity which also engages ring 30. In addition, the electricalconnectors 27 and 50 can be crimped, or soldered to the leads of thediodes 48.

FIGS. 13-15 depict another embodiment of an electrical junction orconnector assembly 60 which differs from electrical connector assembly40 in that electrical connector assembly 60 can include two recesses 70,one for each diode 48, which can be sealed by rubber gaskets 66. Thedual electrical connector 50 can have a longer jumper 52 foraccommodating the positioning of the diodes 48, and the electricalconnectors 27 can have connection portions 25 which are positioned orangled to one side, for alignment purposes. The cover 54 can be shapedappropriately to cover the two recesses 70. Electrical connectorassembly 60 can be mounted to solar panel 10 in a manner similar to thatdescribed above.

Referring to FIGS. 16-22 electrical junction or connector assembly 80can include female electrical terminals 22 which are molded into a body82 and are positioned within or along an electrical engagement face 21,which can be planar. Some embodiments have two or three femaleelectrical terminals 22, and others have four as shown. A planar sealingsurface 83 can be on the electrical engagement face 21 and can surroundthe female electrical terminals 22 for engaging surface 38 and sealingaround the female electrical terminals 22. The body 82 can have arectangular outer perimeter and a generally flat upper surface. Theelectrical terminals 22 can be provided on electrical connectors 27 and50 which are electrically connected to electrical cables 24. Theelectrical cables 24 can extend from the body 82 and can be molded inthe body 82. Diodes 48 can be electrically connected to the femaleelectrical terminals 22 in a manner similar to that described above andin a circuit that can provide bypass circuitry. Access to the diodes 48,circuitry, and other components can be provided by a cover 84 which canbe removably secured to the body 82 by screws 46 or other suitable meansfor maintenance and replacement of components. The female circularconnector sockets 23 on the electrical engagement face 21 of theelectrical connector assembly 80 can be engaged onto the mating maleelectrical terminals 16 a at the electrical connection region 16 of thesolar panel 10. An adhesive layer 32 can be included (FIG. 20) on theelectrical engagement face 21 on the sealing surface 83 around thefemale circular connector sockets 23 of the female electrical terminals22 for securing the electrical engagement face 21 to surface 38 and toprovide sealing around the sockets 23 and the electrical terminals 16 afor sealing out moisture.

In one embodiment, the laminating material 34 and backing 35 can beapplied over the electrical connector assembly 80, in an encapsulatingmanner (FIG. 18). If desired, a hole can be cut in the laminatingmaterial 34 and backing 35 to provide access to the electrical connectorassembly 80. In another embodiment, referring to FIG. 21, a hole 33 canbe cut in the laminating material 34 and backing 35, allowing theelectrical connector assembly 80 and electrical engagement face 21 to bepositioned within the hole 33 for securement to the surface 38 of theelectrical connection region 16, and for engagement with the maleelectrical terminals 16 a located on surface 38 at the bottom of thehole 33. The height of the laminating material 34 and backing 35 can bethe same height as the electrical connector assembly 80 to result in aflush surface. Sealant can be applied around the perimeter of theelectrical connector assembly 80 for sealing purposes. Alternatively, arectangular mounting or housing member or ring 85 (FIG. 22) can beadhered to the solar panel 10 with adhesive layer 30 a and used toprovide an area in which the electrical connector assembly 80 can bepositioned within. The ring 85 can have an inner sealing surface 85 awhich can engage against and seal around the perimeter of the body 82 ofthe electrical connector assembly 80. The ring 85 can be positioned onthe solar panel 10 around electrical connection region 16, before thelaminating material 34 is applied, or after the laminating material 34is applied, and a hole 33 being cut for positioning the ring 85 therein.It is understood that the electrical connector assembly 80 can have lessthan four or more than four female electrical connectors 22.

Referring to FIGS. 23-27, electrical junction or connector assembly 90differs from electrical connector assembly 80 in that electricalconnector assembly 90 can include a circuit board 94 electricallyconnected to female electrical terminals 22 and electrical cables 24. Abody 92 can be positioned or molded over the female electrical terminals22 and the circuit board 94. A cover 84 can provide access to theinterior, circuitry, and to the diodes 48 for maintenance andreplacement of components. The circuit board 94 can include circuitrythat carries or directs the current received from the solar panel 10through the electrical terminals 16 a and out the electrical cables 24.The circuitry can regulate current and voltage, for example, in theevent of over heating or a lightening strike, and can provide bypasscircuitry. The circuit board 94 can eliminate the need for replaceablediodes or heat sinks. The circuit board 94 can also contain logic forother desired functions. In some embodiments, the whole circuit board 94can be encapsulated in the body 92. The electrical connector assembly 90can be laminated or encapsulated such as shown in FIG. 24, positionedwithin a hole 33 as shown in FIG. 27, or can be used in conjunction witha rectangular ring 85 (FIG. 22) in a manner similar to that describedfor electrical connector assembly 80.

FIGS. 28-31 depict another embodiment of an electrical junction orconnector assembly 100. The electrical connector assembly 100 can have agenerally rectangular housing 102 that forms a junction box. The housing102 can have an openable access cover 104 with hinges 112 andprotrusions 114 that engage latches 116 for covering an access opening101. The access opening 101 can face or be in line with the bottom 132of the housing 102. The electrical engagement face 21 is located on theopposite or underside of the bottom 132 and can be planar. A protrusion115 can allow the cover 104 to be lifted or opened for allowing accesswithin the housing 102. It is understood that other suitable covers canbe employed and can be secured with fasteners. Openings 106 and 108 canbe located on opposite walls, sides or ends 105 of the housing 102 toallow electrical cables 24 to enter the housing 102 for electricalconnection therein. The opening 108 can have a fitting 108 a as shown,to provide sealing around electrical cable 24. Such a fitting 108 a canalso be provided for opening 106. An opening 110 can be located on onewall or side 107 for mounting a pressure relief member, valve or vent110 a for relieving pressure differences, such as pressure built upwithin housing 102, or equalizing pressure. A gasket 103 can be employedto provide watertight sealing for the cover 104 and housing 102.

An electrical connector, electrical or circuit member or board 118 (FIG.29) can be inserted in line through the access opening 101 and snapped,engaged, or secured in place in a desired alignment within the housing102 by a locking arrangement 127. The locking arrangement 127 can beself-locking and can include a series of self-locking protrusions 128extending from the bottom 132 of the housing 102. The protrusions 128can engage corresponding locking holes 126 within the circuit board 118to lock the circuit board 118 in position. This can provide a quickself-locking alignment arrangement and can fix or secure the circuitboard 118 in a predetermined position relative to the housing 102. Forexample, four locking protrusions 128 and holes 126 are shown at fourcorners to provide the desire locking and alignment characteristics. Thelocking protrusions 128 and holes 126 can be generally rectangular inshape. The locking protrusions 128 can have angled locking heads 128 a.The locking arrangement 127 can provide simultaneous horizontal andvertical locking and alignment of the circuit board 118 in oneengagement, securement or snapping operation of the locking protrusions128 with holes 126. The circuit board 118 can be inserted into housing102 through access opening 101 in line and in the same orientation thatit engages the locking arrangement 127. The locking protrusions 128 canbe resilient or flexible, and can be configured to also be releasable,and can provide a quick release. It is understood that the lockingprotrusions 128 and holes 126 can have other shapes or configurations.In addition, the locking arrangement 127 can employ other suitablelocking features. The circuit board 118 can be shaped to engage thesides 105 and 107 of the housing 102 for alignment purposes, and can begenerally rectangular. The circuit board 118 can also have notches 118 afor engaging surfaces or structures 120 extending from the bottom 132 ofthe housing 102. This can also provide alignment. The structures 120 canalso provide sealing and isolate openings 106 and 108. In addition, thehousing 102 can have other suitable structures for alignment.Alternatively, the circuit board 118 can be held in place by othersuitable means, including fasteners.

The circuit board 118 can include electrical connectors 140 and 146 onthe underside, having electrical terminals 22 with resilient circularsockets 23. The sockets 23 can be aligned with holes 122 in the circuitboard 118 to provide visual alignment through the circuit board 118. Thelocking arrangement 127 can align the resilient circular sockets 23 withcorresponding electrical connection openings or holes 136 in the bottom132 of the housing 102 (FIG. 31) on the electrical engagement face 21through which the male electrical terminals 16 a on surface 38 of solarpanel 10 can extend or protrude for engagement. The sockets 23 can bepositioned in alignment, over, adjacent, or in the electrical connectionholes 136, depending upon the situation at hand. The electricalengagement face 21 is on the opposite side of the housing 102 from theaccess opening 101 and allows for easy access and alignment for circuitboard 118. A series of holes 124 in the circuit board 118 can allow theattachment and placement of diodes 48 and jumper wires or conductorsrelative to the electrical connectors 140 and 146 on the upper surface.The electrical connectors 140 and 146 can be held in place withsecurement members, tabs 134 or fasteners on the bottom of the circuitboard 118. Alternatively, the electrical connectors 140 and 146 can beheld in place on the bottom 132 of the housing 102.

The electrical connectors 140 and 146 can have various crimping tabs 138for crimping to electrical wires, conductors, diodes 48 or jumpers toobtain the desired electrical circuit, including bypass circuitry. Inaddition, a circuit 125 electrically connected to the electricalconnectors 140 and 146 can be included on the circuit board 118 forproviding desired functions. The circuit 125 can be a circuit board thatis electrically connected to circuit board 118, or can be circuitryformed onto the circuit board 118, and can include desired logiccircuitry. Furthermore, the circuitry provided by the diodes 48,function, and arrangement thereof, can be formed onto the circuit board118. The circuit board 118 can be formed of various suitable materialsdepending upon whether components are to be merely secured thereto, orformed thereon. Although the circuit board 118 has been shown to begenerally planar and rectangular in shape, circuit board 118 can haveother suitable shapes, and can be shaped to fit in different shapedhousings 102. In addition, the electrical connectors 140 and 146 can bepositioned on the upper side of circuit board 118.

The electrical connection holes 136 in the bottom of the housing 102 canbe aligned with, or positioned over or around the corresponding matingmale terminals 16 a on the surface 38 of the electrical connectionregion 16 of the solar panel 10. The mating male terminals 16 a canprotrude through the holes 136 into the housing 102 and engage thesockets 23 of the female electrical connectors 140 and 146. The accessopening 101, the holes 122 in the circuit board 118, and the electricalconnection holes 136 in the bottom of the housing 102, can togetherallow inline visual alignment of the female circular sockets 23 with themating male terminals 16 a. Depending upon the number of electricalconnectors 140 and 146, the configuration and positioning, differentcircuit boards 118 with different electrical circuitry and electricalconnector configurations can be positioned and secured in place intohousing 102. Although five sockets 23 are shown in FIG. 30, it isunderstood that more than five or less than five can be employed andpositioned in different patterns. It is understood that the electricalconnectors can have other suitable configurations depending upon thedesired circuit.

The underside of the bottom 132 of the housing 102 on the electricalengagement face 21, can have an adhesive layer 32, such as silicone oran adhesive tape, for securing the bottom 132 of the housing 102 inplace to the surface 38 of the electrical connection region 16. This canalso provide a planar sealing surface 83 on the electrical engagementface 21 around the electrical connector sockets 23 and the maleelectrical terminals 16 a, for sealing out moisture. Adhesives orsealants can also be applied at the time of adhesion to a surface 38.The electrical connector assembly 100 can be secured to the solar panel10 in various manners such as those previously discussed. In oneembodiment, the housing 102 can be positioned in place after laminationand can be inserted into a hole 33. During installation, the housing 102can be first adhered, secured, or sealed to the surface 38 of the solarpanel 10 by adhesive layer 32. The circuit board 118 can then be snappedinto the housing 102, and at the same time the female electricalterminals 22 engage the male electrical terminals 16 a protruding fromthe surface 38 of the electrical connection region 16 at the bottom ofthe hole 33. Alternatively, the circuit board 118 can already bepositioned or secured within the housing 102, and then the housing 102is secured to the surface 38 while at the same time the femaleelectrical terminals 22 engage the male electrical terminals 16 a. Aring 85 (FIG. 22) can be employed if desired. In addition, the ring 85can be used before the laminating material is applied. In anotherembodiment, the housing 102 can be adhered to the electrical connectionregion 16 and then the laminating material 34 is applied around thehousing 102. Different circuit boards 118 with different electricalconnector configurations can be used in conjunction with different maleterminal 16 a patterns. The electrical face 21 can have a series ofelectrical connection holes 136 which can be used with the differentelectrical connection configurations. Alternatively, the holes 136 canbe different for different housings 102.

While this invention has been particularly shown and described withreferences to example embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the scope of the inventionencompassed by the appended claims.

For example, the electrical terminals on the solar panel 10 can befemale connectors and the electrical terminals on the electricalconnector assemblies can be male terminals. In addition, other suitabletypes of electrical terminals can be employed, such as blade or pinconnectors, etc. Furthermore, although particular shapes have beendescribed for embodiments of the electrical connector assembles, it isunderstood that other suitable shapes are contemplated. The rings 30 and85 can be of other suitable shapes, including other curved and polygonalshapes, and combinations of curved and polygonal shapes. Also, althoughadhesives have been described for securement of components of theelectrical connector assemblies to the solar panels, it is understoodthat other means of securement can be employed, including the use offasteners. In some embodiments, seals such as “O” rings can be used forsealing purposes. In situations where electrical terminals extend abovethe laminating materials of the solar panels, the electrical connectorassemblies do not need to be positioned inside holes in the laminatingmaterial. Although the electrical connector assembles have beendescribed for electrically connecting solar panels, it is understoodthat the electrical connector assemblies can be used in other fields forelectrically connecting other types of components.

1. An electrical connector assembly comprising: an electrical connectorbody having a closed outer perimeter with linear sections, and an uppersurface and a bottom side bounded by the outer perimeter, the bottomside being continuously planar and opposite to the upper surface;multiple female electrical terminals with circular resilient socketscontained within the body, the circular resilient sockets beingpositioned within a continuously planar electrical engagement face ofthe body formed by the continuously planar bottom side of the body, theelectrical engagement face forming a planar sealing surface surroundingthe circular resilient sockets; and a solar panel having an electricalconnection region with a planar mounting surface and protruding circularmale terminals for engagement with the circular resilient sockets of thefemale electrical terminals, said continuously planar bottom side of thebody for engaging the planar mounting surface of the solar panel inplanar surface engagement for providing planar surface sealingtherebetween, and around the circular resilient sockets and the circularmale terminals.
 2. The assembly of claim 1 further comprising anadhesive layer on the planar sealing surface.
 3. The assembly of claim 2in which the female electrical terminals are electrically connected inelectrical circuitry including bypass circuitry.
 4. The assembly ofclaim 3 in which the electrical circuitry includes diodes.
 5. Theassembly of claim 3 in which the electrical terminals are electricallyconnected to a circuit board containing the electrical circuitry.
 6. Theassembly of claim 3 further comprising a removable cover for providingaccess to the electrical circuitry.
 7. The assembly of claim 1 furthercomprising electrical cables electrically connected to the electricalterminals and extending from the connector body.
 8. The assembly ofclaim 1 in which the solar panel includes laminating material, theconnector body being positioned within a hole in the laminating materialfor engaging the circular male terminals, the circular male terminalsbeing located at a bottom of the hole.
 9. A method of forming anelectrical connection with an electrical connector assembly comprising:containing multiple female electrical terminals with circular resilientsockets within an electrical connector body having a closed outerperimeter with linear sections, and an upper surface and a bottom sidebounded by the outer perimeter, the bottom side being continuouslyplanar and opposite to the upper surface, the circular resilient socketsbeing positioned within a continuously planar electrical engagement faceof the body formed by the continuously planar bottom side of the body,the electrical engagement face forming a planar sealing surfacesurrounding the circular resilient sockets; and electrically connectingthe electrical connector body to a solar panel having an electricalconnection region with a planar mounting surface from which matingcircular male terminals protrude by electrically engaging the circularresilient sockets with the mating circular male terminals, saidcontinuously planar bottom side of the body engaging the planar mountingsurface of the solar panel in planar surface engagement for providingplanar surface sealing therebetween, and around the circular resilientsockets and the circular male terminals.
 10. The method of claim 9further comprising securing the electrical engagement face with anadhesive layer on the planar sealing surface.
 11. The method of claim 10further comprising electrically connecting the female electricalterminals in electrical circuitry including bypass circuitry.
 12. Themethod of claim 11 further comprising providing the electrical circuitrywith diodes.
 13. The method of claim 11 further comprising electricallyconnecting the female electrical terminals to a circuit board containingthe electrical circuitry.
 14. The method of claim 11 further comprisingproviding access to the electrical circuitry with a removable cover. 15.The method of claim 9 further comprising electrically connecting thefemale electrical terminals to electrical cables extending from theconnector body.
 16. The method of claim 9 in which the solar panelincludes laminating material, the method further comprising positioningthe connector body within a hole in the laminating material for engagingthe circular male terminals, the circular male terminals being locatedat a bottom of the hole.